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8 COMPONENT REPLACEMENT
It is the law that any service work must be carried out by a competent person, i.e. Gas Safe
registered boiler engineer.
Warning: Before replacing any boiler components, isolate the electrical supply and close the
boiler gas service cock. Allow the boiler to cool.
Always test for gas tightness before and after replacing any gas carrying components or
disturbing any gas connections.
Always carry out electrical system checks i.e. Earth Continuity, Resistance to Earth, Short
Circuit and Polarity with a suitable meter after servicing.
Check the operation of the boiler. (Refer to Sections 6.5 and 6.6).
Ensure that all the controls are returned to their original settings.
8.1 GENERAL ACCESS - Figs 7.1 and 7.2
1. Ensure the electrical supply is isolated and the gas supply is off.
2. Remove the screw at the top centre of the front panel, then lift it up and remove the panel. Release the two screws
securing the control panel and lower the panel.
3. Remove the seven screws securing the room sealed chamber panel and remove the panel, taking care not to damage the
seal.
8.2 DRAINING THE BOILER - Figs. 5.4 and 7.4
Isolate the electricity supply and close the boiler gas service cock, see Fig. 5.4. Allow the boiler to cool.
Heating circuit
1. Drain or isolate the central heating system.
2. Connect suitable pipes to the two boiler drain valves, see Fig. 7.4 and route them to a suitable container.
Open the drain valves using two spanners to prevent damage and support the fitting.
8.3 IGNITION AND SENSING ELECTRODE - Fig. 7.4
Gain access as described in Section 8.1.
1. Pull off the ignition lead from the electrode.
2. Remove the cap screws securing the electrode to the front of the combustion chamber using a 3 mm allen key and
carefully withdraw the electrode.
3. Fit the new electrode assembly with a new gasket and re-assemble in reverse order.
4. Test the boiler, check the ignition and test the combustion as described in Section 7.
8.4 MAIN BURNER
1. Remove the complete burner/fan/air inlet assembly as described in Routine Servicing, Section 7.2.
2. Using a flat screwdriver in the slots of the three spring clips lever each clip out of its retaining groove (see Fig. 7.3) and
carefully lift off the insulation panel to gain access to the burner fixings. It will be necessary to remove the electrode
assembly first as described in Section 8.3.
3. Fit the new burner (with a new gasket) and replace the insulation panel, securing it with the three clips.
4. Re-assemble as described in Routine Servicing, Section 7.5.
5. Test the boiler, check the ignition and test the combustion as described in Section 7.
8.5 FAN - Fig. 7.6
Gain access as described in Section 8.1.
1. Remove the single screw securing the top of the air supply pipe and withdraw it from the fan connection.
2. Remove the wiring connector from the fan, support the fan and remove the two screws securing the fan to the air inlet.
3. Withdraw the fan assembly forwards.
4. Re-assemble in reverse order.
5. Test the boiler, check the ignition and test the combustion as described in Section 7.
8.6 FLUE TEMPERATURE SENSOR WITH BUILT IN THERMAL FUSE - Fig. 7.4
Gain access as described in Section 8.1.
1. Unplug the wire from the flue sensor.
2. Using a 13 mm spanner, turn the sensor 90° anti-clockwise and withdraw it from the heat exchanger.
3. Fit the new sensor and re-assemble in reverse order.
Alpha E-Tec 15, 20, 25R - Component Replacement
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